Tapered canopy for roll-up awning

ABSTRACT

A canopy for use with a retractable, roll-up awning has lateral sides that taper in width from a wider stationary edge to a slightly narrower leading edge. The lateral edges of the canopy may be hemmed and the taper may be designed such that sections of the hems along each edge corresponding in length to a circumference of a roller tube roll up on the roller tube immediately adjacent but laterally further outward from a prior section of hem wrapped around the circumference of the roller tube during the prior rotation of the roller tube. The hems may house wires in a linear pocket defined therein. The wires connect with the roller tube to provide power or control signals.

TECHNICAL FIELD

The technology disclosed herein relates to the design of canopies for retractable, roll-up awnings.

BACKGROUND

Many retractable awning systems, for example, as mounted on the sides of motor homes or over patios or windows, have retraction systems that are actuated by a motor, a spring, or a manually operated gearbox to retract the awning. The fabric canopy of the awning is typically rolled or furled around a roller tube when not in use. The motor, spring, or manually operated gearbox is typically connected to the roller tube to rotate it in clockwise and/or counterclockwise directions, thus operating to furl or unfurl the canopy around or from the roller tube. In other awning implementations, the roller tube may be connected to extension arms (or other extension structures) to extend and contract the arms while the roller tube is rotated by systems mentioned. The canopy fabric is typically constant both in length from a stationary edge mounted on or adjacent a wall or other surface to a leading edge that extends away from the wall and in width between the lateral edges of the canopy.

Prior art FIG. 1 depicts a typical awning 2 supported by extension arms 10 mounted on a wall 4 with the canopy 6 rolled around a roller tube 8 in a furled configuration. As indicated in FIG. 1, when furled, the canopy 6 often has wrinkles and bulges. These wrinkles may result from several causes. In some instances, the material of the canopy 6 stretches or sags and when it is rolled up, the stretched sections can bulge. Alternatively or additionally, if the lateral edges of the canopy 6 are turned over and hemmed, serged, or covered with binding tape, this added, double (or triple) layer of material thickness along the lateral edges causes the lateral edges to stack higher with each rotation of the roller tube 8. Bulging edges of the canopy material form on the lateral ends of the roller tube 8 and the canopy 6 does not roll flat against the roller tube 8. Further, the outer layers of canopy material may be placed under tension directed laterally inward because of the single layer of canopy material on the roller tube 8 between the lateral edges. The lateral edges thus tend to slide laterally inward and cause bunching of the canopy material along the roller tube 8. Not only is this bunching, bulging, and wrinkling unsightly, but it can also cause stress on and weakening of those areas of the canopy material that are pinched and wrinkled by the lateral slippage of the canopy 6 when it is furled around the roller tube 8.

The information included in this Background section of the specification, including any references cited herein and any description or discussion thereof, is included for technical reference purposes only and is not to be regarded subject matter by which the scope of the invention is to be bound.

SUMMARY

A unique canopy design for use with a retractable, roll-up awning is disclosed herein as having lateral sides that taper in width from a wider stationary edge to a slightly narrower leading edge. The lateral edges of the canopy may be hemmed and the taper may be designed such that sections of the hems along each edge corresponding in length to a circumference of a roller tube roll up on the roller tube immediately adjacent but laterally further outward from a prior section of hem wrapped around the circumference of the roller tube during the prior rotation of the roller tube.

In one implementation a canopy formed of a material is provided for an awning having a roller tube around which the canopy is furled and unfurled. The canopy has a leading edge, a stationary edge, a first tapered lateral edge, and a second tapered lateral edge. The first tapered lateral edge extends at an acute angle between the leading edge and the stationary edge. The second tapered lateral edge extends at the same acute angle between the leading edge and the stationary edge. Each tapered lateral edge tapers laterally toward the other. Each tapered lateral edge includes an area of greater thickness than a thickness of the material for a substantially constant width along a length of each lateral edge. One of the leading edge or the stationary edge is configured to attach along its length to the roller tube. The length of the one of the leading edge or the stationary edge is shorter than a length of the other of the leading edge or the stationary edge.

In another implementation a retractable awning has a canopy and a roller tube around which the canopy made of a material is furled and unfurled. The canopy has a leading edge, a stationary edge, a first tapered lateral edge, and a second tapered lateral edge. The first tapered lateral edge extends at an acute angle between the leading edge and the stationary edge. The second tapered lateral edge extends at the same acute angle between the leading edge and the stationary edge. Each tapered lateral edge tapers laterally toward the other. Each tapered lateral edge includes an area of greater thickness than a thickness of the material for a substantially constant width along a length of each lateral edge. One of the leading edge or the stationary edge is attached to the roller tube along its length and around which the canopy is furled and unfurled. The length of the one of the leading edge or the stationary edge is shorter than a length of the other of the leading edge or the stationary edge.

In a further implementation a canopy is provided for an awning having a roller tube around which the canopy is furled and unfurled. The canopy has a leading edge, a stationary edge, a tapered first lateral edge, and a second lateral edge. The tapered first lateral edge may extend at an acute angle between the leading edge and the stationary edge. The second lateral edge may extend between the leading edge and the stationary edge. The tapered first lateral edge tapers laterally inward toward the second lateral edge. One of the leading edge or the stationary edge is configured to attach along its length to the roller tube. The length of the one of the leading edge or the stationary edge is shorter than a length of the other of the leading edge or the stationary edge. One or more wires are attached to and extend along the length of the first tapered lateral edge.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other features, details, utilities, and advantages of the present invention will be apparent from the following more particular written description of various embodiments of the invention as further illustrated in the accompanying drawings and defined in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevation view of a prior art awning with a furled canopy suffering from bulging, bunching, and wrinkling problems with the canopy material.

FIG. 2 is a top plan view of a tapered canopy with the lateral edges evenly tapering slightly such that the width of the leading edge is less than the length of the fixed edge.

FIG. 3 is a front, top perspective view of an awning mounted to the side of a structure with a tapered canopy in an unfurled position.

FIG. 4 is a cross section of a hemmed edge of the canopy enclosing a wire as indicated in by line 4-4 in FIG. 3.

FIG. 5 is a cross section view of an alternative tapered canopy edge wherein a wire is adhered along the canopy edge by a flange.

FIG. 6 is an isometric view of a portion of the leading edge of the awning of FIG. 5 detailing a wire in an edge hem connecting to the roller tube to power lights mounted on the roller tube.

FIG. 7 is an enlarged cross-section view of an end portion of a roller tube of an awning with a tapered canopy rolled around the roller tube in a furled state.

DETAILED DESCRIPTION

A new canopy design for a retractable roller awning or similar blind or roller shade structure is proposed herein that significantly mitigates the problems of bunching and wrinkling of canopy material when the canopy is furled about a roller tube, especially when a canopy is made with lateral edges that are hemmed, serged, or edged with binding tape. An exemplary implementation of such a canopy 106 is depicted in FIG. 2. The canopy may be made of a woven fabric, a polymer film, or other sheet-like material. The canopy 106 has a leading edge 116 that is typically connected along the length of a roller tube of the awning and a stationary edge 114 that is typically mounted along or adjacent a wall or other structure. However, in other implementations, the stationary edge could be mounted to a roller tube that is mounted on or adjacent to the wall while the leading edge is supported by a bar or other support that extends away from the wall as the canopy unfurls from the roller tube.

In a first configuration depicted in FIG. 2, the lateral edges 118 a, 118 b of the canopy 106 may symmetrically taper toward each other slightly such that the width of the leading edge 116 is less than the width of the stationary edge 114. An angle θ may thereby be defined between each lateral edge 118 a, 118 b and a line a perpendicular to each of the stationary edge 114 and the leading edge 116 and intersecting a corner of the canopy 106 where one or the other of the lateral edges 118 a, 118 b intersects the stationary edge 114. The angle α is thus the angle of taper of the lateral edges 118 a, 118 b. It should be appreciated that in an alternate embodiment the width of the leading edge may be greater than the width of the stationary edge. In such a configuration, the angle of the taper extends from the leading edge to the stationary edge.

In a second configuration (not shown) in which the roller tube is mounted adjacent the wall or surface, the lateral edges of the canopy may symmetrically taper away from each other slightly as the canopy unfurls such that the width of the leading edge is greater than the width of the stationary edge. The angle θ may thereby be defined between each lateral edge and a line α perpendicular to each of the stationary edge and the leading edge and intersecting a corner of the canopy where one or the other of the lateral edges intersects the leading edge. Again, it should be appreciated that in an alternate embodiment the width of the stationary edge may be greater than the width of the leading edge. In such a configuration, the angle of the taper extends from the stationary edge to the leading edge.

Further, each of the lateral edges 118 a, 118 b may be formed as a hem 120 a, 120 b whereby the lateral edges 118 a, 118 b are folded over a certain constant width H_(w) and thereby form a double layer of canopy material. The hems 120 a, 120 b may be sewn or stitched, held together by an adhesive, heat-sealed together, or secured by any other suitable method of holding the two layers of canopy material together. The hems 120 a, 120 b of the canopy 106 are thus twice as thick as the majority of the canopy material between the lateral edges 118 a, 118 b. While the discussion herein focuses on hemmed edges of the canopy material, the disclosure is equally applicable to canopy edges that are serged, edged with binding tape, or are otherwise finished in a manner that adds to the thickness or bulk of the edges.

In order to ensure that the canopy 106 with hemmed edges 120 a, 120 b rolls up taut on a roller tube without wrinkling or bulging at the ends, the taper angle θ and the related width of the taper or flare F₁ may be calculated as a function of the width H_(w) of each hem 120 a, 120 b (or the serged area or the width of the binding tape) and a circumference R_(cir) (or π·D, where D is the diameter) of the roller tube such that with each revolution of the canopy 106 around the roller tube, the lateral edges 118 a, 118 b are spaced substantially a hem width H_(w) beyond the position of the lateral edges 118 a, 118 b in the prior wrap of the canopy 106. Such an exemplary formula may be derived as follows:

${{\tan \; \theta} = \frac{F_{l}}{L_{c}}},$

where F₁ is the width of the widest point of the flare or taper at the leading edge 116 between the leading edge 116 and the normal line α, and L_(c) is the length of the canopy between the stationary edge 114 and the leading edge 116. Thus,

F₁=L_(c) tanθ.

Further,

${\theta = {\tan^{- 1}\left( \frac{H_{w}}{R_{cir}} \right)}},$

where the taper angle θ is an acute angle of each tapered edge with respect to the normal line α perpendicular to the leading edge or the stationary edge. Thus,

${F_{l} = {L_{c}{\tan \left( {\tan^{- 1}\left( \frac{H_{w}}{R_{cir}} \right)} \right)}}},$

which reduces to

$F_{l} = {{L_{c}\left( \frac{H_{w}}{R_{cir}} \right)}.}$

Using a formula such as this allows each successive revolution of the hems 120 a, 120 b around the roller tube to roll adjacent to but outside of the position of the lateral edge 118 a, 118 b of the prior coil or wrap of the canopy 106 around the roller tube.

An alternate implementation of an awning 102 with a tapered canopy 106 is shown in FIG. 3. As in the example of FIG. 2, the canopy 106 of FIG. 3 has a stationary edge 114 and a leading edge 116. The stationary edge 114 is attached via a bar 112 or other structure to a wall 104 or other surface, e.g., of a recreational vehicle, house, or building. The leading edge 106 is attached to a roller tube 108 that is supported by a pair of collapsible extension arms 110 that are mounted to the side of the wall 104. The lateral edges 118 a, 118 b of the canopy 106 taper or flare in a similar manner as in FIG. 2. The lateral edges 118 a, 118 b of the canopy 106 also have hems 120 a, 120 b whereby a narrow width of the fabric of the canopy 106 is folded over between the stationary edge 114 and the leading edge 116 and hemmed.

In the embodiment of FIG. 3, one of the hems 120 b also includes a wire 122 or cable that is enveloped in the fold of the hem 120 b and is thus retained therein along the length of the lateral edge 118 b from the wall 104 to the roller bar 108. The hem 120 b provides a linear pocket 124 to run wires 122, e.g., a power cord, control leads, or other wires or cables from a power source or control switch in or on the camper or other structure forming the wall 104 to provide power or control signals to the motor or other features in the roller tube 108 at the end of the awning 102. Alternatively, binding tape affixed along the lateral edges may provide a similar linear pocket for running wires therethrough. FIG. 4 depicts a detailed cross section of the hem 120 b of the canopy 106 of FIG. 3 that envelopes the wires 122 in the linear pocket 124 adjacent the lateral edge 118 b. While the embodiment of FIGS. 3 and 4 depicts wires 122 secured within only one of the hems 118 b, it should be apparent that cords, cable, or wires could be carried within either or both of the hems 120 a, 120 b on both lateral sides 118 a, 118 b of the canopy 106.

FIG. 5 depicts an alternate embodiment of a canopy 106′ that carries wires 122′ along a lateral edge 118′. In this embodiment, the wires 122′ are encased in an extruded tube 126 that defines a linear pocket 124′ through which the wires 122′ run. A flange 128 extends radially from a sidewall of the extruded tube 126 along the entire length of the extruded tube 126. The flange 128 can be sewn, stitched, serged, adhered, heat sealed, or otherwise affixed to the lateral edge 118′ of the canopy 106′. While there is not a traditional hem in this embodiment, the flange 128 and extruded tube 126 add thickness and bulk to the lateral edge 118′of the canopy 106′ and can thus cause similar bulking and wrinkling problems as in the prior hemmed embodiments, with or without wires running therethrough.

Tapering the canopy 106′ in a manner similar to FIG. 2 for an awning using a flanged wire as shown in FIG. 5 can provide similar improved results in the reduction or removal of wrinkles or bulk from the canopy 106′ when furled about a roller tube. Thus, the width of a taper of each tapered lateral edge 118′ at a widest point may be defined by a length of the canopy 106′ between the leading edge and the stationary edge multiplied by a quotient of a combined width of the extruded tube 126 and the linear flange 128 divided by a circumference of the roller tube. Similarly, the desired taper angle can be computed as the inverse tangent of a quotient of a combined width of the extruded tube 126 and the linear flange 128 divided by a circumference of the roller tube. In this embodiment, the opposite lateral edge may not be hemmed or otherwise thicker than the canopy material and thus may not need to be tapered as there would be no concern about material bulking on that lateral edge.

Similarly, it should be apparent that only one edge need be tapered in any of the embodiments disclosed herein. For example, only one lateral edge of the canopy need be hemmed or covered with binding tape in order to carry a wire from the stationary edge to the leading edge. Thus, while the hemmed edge is tapered to resist the binding problem upon furling, the opposite lateral edge may remain straight (i.e., perpendicular to both the leading edge and the stationary edge).

FIG. 6 depicts one exemplary implementation of an awning 102 having a canopy 106, which is shown unfurled from a roller tube 108. One or more wires 122 is housed within the hem 120 a of the canopy 106 and may exit adjacent the roller tube 108 through a small reinforced hole in the canopy material in the hem 120 a. In this embodiment, the roller tube 108 is designed with one or more LED light strips 132 or other lighting elements that are exposed to light an area underneath the awning 102 when the canopy 106 is fully unfurled. The roller tube 108 may have a small aperture 134 or other receptacle through or into which the wires 122 may be inserted to connect to wiring controlling and/or powering the light strips 132 on the roller tube 108. Alternatively, the end of the wires 122 may be provided with a plug for insertion into an electrical receptacle housed in the aperture 134 to connect the wires 122 with desired wired systems within the roller tube 108.

The canopy 106 is depicted in FIG. 7 at one end of the roller tube 108 in a furled state. As shown, the tapered canopy 106 winds around the roller tube 108 such that in successive windings, the hem 120 lays adjacent to and laterally further outward from the position of the hem 120 at a same longitude of a circumference of the roller tube as the immediately prior winding, i.e., the edge 130 of the canopy fabric turned under for the hem 130 of the present winding sits adjacent the lateral edge 118 of the prior winding of the canopy 106. In the embodiment shown in FIG. 7, the wires 122 in the linear pocket 124 lay relatively flat against the roller tube 108 rather than on top of a prior layer of canopy 106 or hem 120. In this manner, large bulging of the canopy material at the lateral end 118 of the canopy 106 is avoided. Further, the layering of the hems 120 next to each other stretches the canopy material laterally outward such that the likelihood of wrinkling or bunching of the canopy material is avoided as the canopy 106 is rolled up on the roller tube 108.

It should be understood that, as noted above, the taper in the canopy could run an opposite direction such that, in successive windings, the hem lays adjacent to and laterally further inward from the position of the hem at a same longitude of a circumference of the roller tube as the immediately prior winding, i.e., the lateral edge of the present winding sits adjacent the edge of the canopy fabric turned under for the hem of the prior winding of the canopy. In contrast to the embodiment shown in FIG. 7, the hem or wires therein lay relatively flat against a prior layer of canopy rather than bulking on top of the hem of the prior winding. In this manner, large bulging of the canopy material at the lateral ends of the canopy is avoided.

Although various embodiments of this invention have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention. All directional references (e.g., proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present invention, and do not create limitations, particularly as to the position, orientation, or use of the invention. Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and may include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to each other. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the basic elements of the invention as defined in the following claims. 

What is claimed is:
 1. A canopy for an awning, wherein the awning comprises a roller tube around which the canopy is furled and unfurled, the canopy formed of a material and comprising a leading edge; a stationary edge; a first tapered lateral edge extending at an acute angle between the leading edge and the stationary edge; and a second tapered lateral edge extending at the acute angle between the leading edge and the stationary edge; wherein each tapered lateral edge tapers laterally toward the other; each tapered lateral edge includes an area of greater thickness than a thickness of the material for a substantially constant width along a length of each lateral edge; one of the leading edge or the stationary edge is configured to attach along its length to the roller tube; and the length of the one of the leading edge or the stationary edge is shorter than a length of the other of the leading edge or the stationary edge.
 2. The canopy of claim 1, wherein the acute angle of each tapered edge with respect to a line perpendicular to the leading edge or the stationary edge is defined by an inverse tangent of a quotient of the constant width of the hem divided by a circumference of the roller tube.
 3. The canopy of claim 1, wherein a width of a taper of each tapered lateral edge at a widest point is defined by a length of the canopy between the leading edge and the stationary edge multiplied by a quotient of the constant width of the hem divided by a circumference of the roller tube.
 4. The canopy of claim 1, wherein the first tapered lateral edge defines a linear pocket along the length of the first tapered lateral edge; and one or more wires extend through the linear pocket along the length of the first tapered lateral edge.
 5. The canopy of claim 4, wherein the linear pocket is defined by a hem formed by a fold of the material at the first tapered lateral edge or a by binding tape running the length of the first tapered lateral edge.
 6. The canopy of claim 1, wherein, in a furled state, the canopy winds around the roller tube such that in successive windings, the area of greater thickness lays adjacent to a position of the area of greater thickness at a same longitude of a circumference of the roller tube as an immediately prior winding.
 7. A retractable awning comprising a canopy made of a material having a leading edge; a stationary edge; a first tapered lateral edge extending at an acute angle between the leading edge and the stationary edge; and a second tapered lateral edge extending at the acute angle between the leading edge and the stationary edge; each tapered lateral edge tapers laterally toward the other; and each tapered lateral edge includes an area of greater thickness than a thickness of the material for a substantially constant width along a length of each lateral edge; and a roller tube to which one of the leading edge or the stationary edge is attached along its length and around which the canopy is furled and unfurled; wherein the length of the one of the leading edge or the stationary edge is shorter than a length of the other of the leading edge or the stationary edge.
 8. The retractable awning of claim 7, wherein the acute angle of each tapered edge with respect to a line perpendicular to the leading edge or the stationary edge is defined by an inverse tangent of a quotient of the constant width of the hem divided by a circumference of the roller tube.
 9. The retractable awning of claim 7, wherein a width of a taper of each tapered lateral edge at a widest point is defined by a length of the canopy between the leading edge and the stationary edge multiplied by a quotient of the constant width of the hem divided by a circumference of the roller tube.
 10. The retractable awning of claim 7, wherein, in a furled state, the canopy winds around the roller tube such that in successive windings, the area of greater thickness lays adjacent to a position of the area of greater thickness at a same longitude of a circumference of the roller tube as an immediately prior winding.
 11. The retractable awning of claim 7, wherein the first tapered lateral edge defines a linear pocket along the length of the first tapered lateral edge; and one or more wires extend through the linear pocket along the length of the first tapered lateral edge.
 12. The retractable awning of claim 11, wherein the linear pocket is defined by a hem formed by a fold of the material at the first tapered lateral edge or a by binding tape running the length of the first tapered lateral edge.
 13. The retractable awning of claim 11, wherein an aperture is defined in the material adjacent the roller tube and in communication with the linear pocket through which an end of the one or more wires protrudes; and the roller tube further comprises a receptacle that receives the end of the one or more wires protruding from the aperture in the material.
 14. The retractable awning of claim 11, wherein the roller tube further comprises a light fixture electrically connected to the one or more wires in the linear pocket.
 15. A canopy for an awning, wherein the awning comprises a roller tube around which the canopy is furled and unfurled, the canopy comprising a leading edge; a stationary edge; a tapered first lateral edge extending at an acute angle between the leading edge and the stationary edge; a second lateral edge extending between the leading edge and the stationary edge; wherein the tapered first lateral edge tapers laterally toward the second lateral edge; one of the leading edge or the stationary edge is configured to attach along its length to the roller tube; and the length of the one of the leading edge or the stationary edge is shorter than a length of the other of the leading edge or the stationary edge; and one or more wires attached to and extending along the length of the tapered first lateral edge.
 16. The canopy of claim 15 further comprising an extruded tube defining a linear pocket in which the one or more wires are housed; and a linear flange extending from an outer surface of the extruded tube along a length of the extruded tube and attached to the tapered first lateral edge along the length of the tapered first lateral edge.
 17. The canopy of claim 16, wherein the acute angle of the tapered first lateral edge with respect to a line perpendicular to the leading edge or the stationary edge is defined by an inverse tangent of a quotient of a combined width of the extruded tube and the linear flange divided by a circumference of the roller tube.
 18. The canopy of claim 16, wherein a width of a taper of the tapered first lateral edge at a widest point is defined by a length of the canopy between the leading edge and the stationary edge multiplied by a quotient of a combined width of the extruded tube and the linear flange divided by a circumference of the roller tube.
 19. The canopy of claim 16, wherein, in a furled state, the tapered canopy winds around the roller tube such that in successive windings, the extruded tube and the linear flange lie adjacent to a position of the extruded tube and the linear flange at a same longitude of a circumference of the roller tube as an immediately prior winding.
 20. The canopy of claim 15, wherein, in a furled state, the tapered canopy winds around the roller tube such that in successive windings, the one or more wires lie adjacent to a position of the one or more wires at a same longitude of a circumference of the roller tube as an immediately prior winding. 